Package for hip prosthesis

ABSTRACT

A clamshell package supports a hip prosthesis so that modular pads and/or a modular distal sleeves can be added during surgery so that sterility is maintained while achieving a custom fit for the patient.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to packages for prosthetic devices, and more particularly a package for supporting a hip stem/hip prosthesis wherein a cassette having half portions supports the prosthesis at least around the proximal end thereof so that modular pads and modular distal sleeves can be assembled thereto while supported by the packages, prior to hip stem surgery.

2. General Background

There are a number of hip prosthesis devices that are commercially available which use a configuration that includes a lower stem which is generally cylindrical, a larger proximal end portion that includes anterior and posterior surfaces, and also a neck region to which an acetabular ball is affixed.

There are commercially available modular hip implant systems that provide proximal modules and distal modules. Because of the irregular shape of such hip implants and of the protruding modular parts which are to be added (such as modular pads and distal sleeves), complete assembly on a surgical table and during surgery can be very difficult. Another problem is that sterility must be maintained during installation of modular parts and removal of the implant from its package during surgery.

There are four commercially modular hip systems known to the Applicant, each of which addresses this problem in a different manner.

The Infinity hip system from Dow Corning Wright uses a vise to clamp the stem in place while the proximal module is applied with a mallet. This vise is cumbersome and could possibly cause damage to the stem. This implant system does not use a distal sleeve.

The Omni-Flex hip from Osteonics has a distal sleeve which is applied by laying the stem end up on the proximal end and pounding the distal sleeve in place with a mallet. This method can potentially cause problems because it allows the trunnion to rest on the table where it can possibly be damaged. Also the hip stem could possibly be knocked off the table during this installation, damaging the hip and compromising sterility.

The S-ROM Hip, from Joint Medical Products, has a proximal module which is placed in the femur first followed by the stem which is tapped into place at the proper orientation. This stem is assembled in the femur as opposed to preassembly.

The APR II, from Intermedics, has an open ended distal sleeve which is applied by using an impactor which is struck with a mallet.

An example of a modular hip prosthesis system can be seen in U.S. Pat. No. 4,995,883, entitled "Modular Hip Prosthesis", issued Feb. 26, 1991, and assigned to the assignee of this application, Smith & Nephew Richards Inc.

There are some patented constructions for packages and package assemblies that have been patented. As an example, U.S. Pat. No. 4,921,096, issued to Taut, Inc. describes a package assembly for a pointed surgical instrument. One part of the package comprises a clamshell-type portion which is openable so that the non-pointed end of the instrument can be grasped and the instrument removed or replaced in the package without touching the pointed end. The clamshell portion may be open or closed as required. The package is in two parts which are hinged together. One part cannot be opened and encloses the sharp point. The other part has the clamshell-type opening whereby when opened the non-sharp end of the product may be grasped to remove it from the package. After use, the product may be reintroduced into the package, the clamshell opening is closed again and the package may be disposed of.

U.S. Pat. No. 4,872,551 describes a clamshell blister pack for pliers wherein the head of the pliers is held in the pack and the handles can be manipulated by the customer. The package in the '551 patent includes a pair of opposing mirror-image panels having recesses and joined along a common lower end to form a base portion. The base portion is provided with a pair of openings for accommodating the handles of the pliers. The head of the pliers is held in the package but the handles protrude from the base of the package and can be manipulated to a specified extent by the customer prior to purchase without opening the package.

SUMMARY OF THE INVENTION

Each of the above discussed systems addresses the assembly problem in a slightly different way. However, the design of the present invention is unique because it provides protection for the product during shipping and maintains sterility until the product is ready for use. In the operating room, the package then becomes an assembly device which can be disposed of after the surgery. Because the clamshell supports the prosthesis, the implant cannot slide or tilt during assembly, which could cause the sleeve or pad to have inadequate engagement with the stem. By using the package of the present invention, the surgeon can be insured that the sleeves and pads will be applied consistently every time. Some modular systems which do not have a fixture, run the risk of improper seating of the modules due to movement or rocking of the prosthesis.

The present invention thus provides an improved instrument package intended for use with a medical prosthesis such as modular hip prosthesis system of the type, e.g., shown and described in U.S. Pat. No. 4,995,883, entitled "Modular Hip Prosthesis", issued Feb. 26, 1991, and incorporated herein by reference.

The present invention provides a package with a cassette having two trays and a hinged web component which snaps around the implant to encase it.

During surgery, the proper pre-selected modular pads and or distal sleeves are opened along with the package. The prosthesis and cassette assembly is then placed end up on the operating room table, and the distal sleeve can be driven onto the stem using a spring loaded driver. The cassette is then opened and the pads are driven into place using an impact driver instrument. Two snaps are used to keep the cassette from opening during impact.

The present invention provides a container for the carriage of a modular hip prosthesis having a lower stem, a proximal portion with anterior and posterior sides, a neck portion, and modular pads and/or a distal sleeve. The apparatus includes a cassette having a pair of halves of corresponding size, each having a face that abuts the face of the other upon closure, and each half having a recess that conforms generally to the outer surface of the prosthesis.

A bore of the cassette is formed upon closure, the bore surrounding at least a lower end portion of the stem of the prosthesis and extending between the recesses so that a distal sleeve can be added to the stem while the prosthesis is occupying a position in the cassette.

The cassette has a shape that closely supports the entire proximal end of the prosthesis so that modular pad can be added to the prosthesis while the prosthesis is being supported by the cassette.

Each cassette half preferably has a recess that cradles an anterior or posterior half of the prosthesis.

The cassette is comprised of a web member that connects the cassette halves at respective peripheral portions of each cassette half.

A bore is provided that defines a cylindrical opening upon closure of the cassette halves that encircles the stem.

The bore is generally cylindrical and preferably of uniformed diameter.

The cassette is generally rectangularly shaped having parallel side wall portions and the prosthesis is oriented along an axial line that is generally parallel to the parallel side walls of the cassette.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:

FIG. 1 is a perspective exploded view of the preferred embodiment of the apparatus of the present invention;

FIG. 2 is an end view of the preferred embodiment of the apparatus of the present invention shown in a fully opened positioned;

FIG. 3 is an end view of the preferred embodiment of the apparatus of the present invention illustrating closure;

FIG. 4 is a top view of the preferred embodiment of the apparatus of the present invention in a fully opened position;

FIG. 5 is a side view of the preferred embodiment of the apparatus of the present invention;

FIG. 6 is a side view of the preferred embodiment of the apparatus of the present invention illustrating the addition of a distal sleeve to the prosthesis;

FIG. 7 is a perspective view of the preferred embodiment of the apparatus of the present invention illustrating the use of an impact driver to add a distal sleeve to the prosthesis;

FIG. 8 is another perspective view of the preferred embodiment of the apparatus of the present invention illustrating an impact driver, distal sleeve, and prosthesis in exploded perspective view; and

FIG. 9 is a fragmentary sectional view of the impact driver of FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1-6 illustrate the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10. Prosthesis package apparatus 10 includes a first plastic tray 11 having a well 12 which is separated into well sections 12b, 12c with divider 12a.

A second plastic tray 13 includes a well 14 for receiving the plastic tray 11 thereinto. The well section 12b receives clamshell cassette 15. In the preferred embodiment, a hip prosthesis 21 (see FIG. 6) extends out the end of the cassette 15 so that a distal sleeve can be added thereto using an impact driver. Each tray 11, 13 can have a peripheral flange 11a, 13a respectively to which release liners (not shown) can be affixed with adhesive, for example, so that the contents of each tray 11, 13 can be maintained sterile.

The clamshell cassette 15 includes a pair of cassette half portions 16, 17 connected together with longitudinally extending web 18. Each cassette half 16, 17 provides respective storage depressions 19, 20 each conforming to the outer surface of a hip prosthesis body 21. The prosthesis body 21 and each storage depression 19, 20 include neck region 22, proximal section 23, and a distal stem section 24. Each cassette half 16, 17 includes a peripheral side wall 25, 26 respectively, the peripheral side wall 25 being comprised of wall sections 27a-d and the peripheral side wall 26 being comprised of wall sections 28a-d.

Each cassette half 16, 17 respectively provides an interior face 29, 30 portion, the faces 29, 30 abutting upon closure of the cassette 15. Each cassette half is equipped with a curved recess for placement of the users thumb, including thumb recesses 31, 32 that assist in opening halves 16, 17. Arrow 33 in FIGS. 1 and 3 illustrates closure of the cassette halves about hinges 18a, 18b. The cassette halves 16, 17 can be maintained in a closed position as shown in FIGS. 5 and 6 by the attachment of a pair of closure snaps 34, 35 into correspondingly placed snap wells 36, 37.

Each storage depression 19, 20 is preferably of corresponding size, with the storage depressions 19, 20 respectively containing an anterior or a posterior half portion of the prosthesis 21 upon closure, as illustrated in FIGS. 5 and 6. Each depression 20, 21 includes a depression for a modular pad, the pad depressions being designated as 38, 39 respectively. Each cassette half 16, 17 includes semicircular opening 40, 41. The semicircular openings 40, 41 define a distal sleeve opening 46 upon closure, as shown in FIG. 8. In FIG. 4, installation of a modular pad 42 is shown using impact driver 56. The driver 56 loads the pad into it recess and the casette half 17 supports the prosthesis 21.

Distal sleeve 44 has a sleeve bore 45 with an internal diameter that is sized to fit upon the distal stem 21 portion of the prosthesis 21. Internal diameter 47 of sleeve opening 46 is larger than the external diameter of sleeve 44, as shown in FIGS. 4, 5, and 6. In this fashion, the entire prosthesis 21 can be closely conformed to the depressions 19, 20 while the opening 46 is sized to receive the larger diameter distal sleeve 44.

FIGS. 7 and 8 illustrate attachment of a distal sleeve 44 to the stem 24 portion of the prosthesis 21. The cassette 15 is first supported in a closed position with the stem 24 extending outwardly of the opening 46. The distal sleeve 44 is then placed upon the distal stem by registering the distal stem 24 into the internal bore 45 of the distal sleeve 44. An impact driver 50 having a tool tip portion 51 is placed upon the hemispherical end 49 of the distal sleeve 44.

A hemispherical recess 52 can be provided on the tool tip 51. The impact driver 50 then applies a load to the distal sleeve forcing it on the distal stem. During this operation, the closed cassette 15 fully supports the prosthesis 21 during the impact driving. Arrows 53 illustrate the direction of movement of the distal sleeve 44 onto the distal stem 24. An instrument tray 54 having an interior 58 can have rectngular receptacle 57 sized to receive the cassette 15. The receptacle can be used to support the cassette 15 during installation of the modular sleeve 44. When installing the sleeve 44, receptacle 57 in instrument tray 54 surrounds the lower end of and supports the cassette 15. Because the apparatus 10 can be sterile, protecting the sterility of prosthesis 21, the user's hand 55 can be any operating room person, such as a doctor or nurse, wearing sterile gown and gloves. Thus, the present invention maintains a sterile integrity of the prosthesis 21 yet allowing change in prosthesis size and shape using the modular components.

It should be understood from the above that the entire cassette 15, prosthesis 21, modular pads 42, 43 and distal sleeve 44 can be maintained in a sterile condition during the entire surgery. The prosthesis can be custom sized for a particular patient with minimum risk of damage to the prosthesis or of contamination of the prosthesis.

The following table lists the part numbers and part descriptions as used herein and as appearing in the attached drawings.

                  TABLE                                                            ______________________________________                                         PARTS LIST                                                                     Part Number     Description                                                    ______________________________________                                         10              package                                                        11              plastic tray                                                   11a             peripheral flange                                              12              well                                                           12a             divider                                                        12b-12c         well sections                                                  13              plastic tray                                                   13a             peripheral flange                                              14              well                                                           15              clamshell cassette                                             16              cassette half                                                  17              cassette half                                                  18              web                                                            18a-18b         hinges                                                         19              storage depression                                             20              storage depression                                             21              hip prosthesis                                                 22              neck region                                                    23              proximal section                                               24              distal stem                                                    25              peripheral sidewall                                            26              peripheral sidewall                                            27a-d           wall sections                                                  28a-d           wall sections                                                  29              inside face                                                    30              inside face                                                    31              thumb recess                                                   32              thumb recess                                                   33              arrow                                                          34              closure snap                                                   35              closure snap                                                   36              snap well                                                      37              snap well                                                      38              depression for pad                                             39              depression for pad                                             40              semicircular opening                                           41              semicircular opening                                           42              modular pad                                                    43              modular pad                                                    44              distal sleeve                                                  45              sleeve bore                                                    46              sleeve opening                                                 47              internal diameter                                              48              impact tool opening                                            49              distal end                                                     50              impact tool                                                    51              tool tip                                                       52              tool tip recess                                                53              arrows                                                         54              instrument tray                                                55              users hand                                                     56              impact driver                                                  57              instrument tray receptacle                                     58              instrument tray interior                                       59              instrument tray sidewall                                       ______________________________________                                    

Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. 

What is claimed as invention is:
 1. A container for carriage of a modular hip prosthesis having a lower stem, a proximal portion with anterior and posterior sides, a neck portion, modular pads attachable to the proximal portion, and a distal sleeve attachable to the stem comprising:a) a cassette having a pair of halves of corresponding size, each having a face that abuts the face of the other upon closure, and each half having a recess that conforms generally to the outer surface of the prosthesis; b) a bore of the cassette being formed by the recesses upon closure, the bore being sized and shaped to surround a contained hip prosthesis that is to be positioned to extend between the recesses; c) the bore having a larger portion that closely conforms to a hip prosthesis proximal portion having anterior and posterior sides, and neck portion, and the bore having a smaller portion for accommodating the hip prosthesis stem; and d) the recess having portions for receiving a modular pad of a prosthesis assembled thereto.
 2. The apparatus of claim 1 wherein each of the cassette recesses are positioned to closely support the entire proximal end of the prosthesis so that the cassette supports the prosthesis during attachment of modular pads thereto.
 3. The apparatus of claim 1 wherein each of the cassette halves has a recess that respectively cradle an anterior and a posterior half of the prosthesis.
 4. The apparatus of claim 1 wherein the cassette is further comprised of a web member that connects the cassette halves at respective peripheral portions of each cassette half.
 5. The apparatus of claim 1 wherein the bore defines a cylindrical opening portion upon closure of the cassette halves.
 6. The apparatus of claim 1 wherein a portion of the bore is cylindrical and of generally uniform diameter.
 7. The apparatus of claim 1 wherein the cassette is generally rectangularly shaped and having parallel side wall portions and the prosthesis is oriented along an axial line that is generally parallel to the parallel side walls.
 8. A container for a modular hip prosthesis having a lower generally cylindrical stem, a proximal portion with anterior and posterior sides and a neck portion comprising:a) a cassette having a pair of cassette halves, each having an inner face that abuts the inner face of the other upon closure of the cassette, and the cassette having a recess portion that conforms generally to the prosthesis; b) a bore of the cassette being formed by the recess portions upon closure, the bore for surrounding the stem portion of the prosthesis and being spaced therefrom upon closure so that a sleeve can be added to the stem while the prosthesis is occupying a position in the recesses of the cassette; and c) an outer housing for containing both the cassette halves and the prosthesis in such a way as to envelop same.
 9. A container for carriage of a modular hip prosthesis having a lower cylindrical stem, a proximal portion with anterior and posterior sides, a neck portion, and modular pads and distal sleeves for changing the outer shape of the prosthesis comprising:a) cassette means for holding a hip prosthesis and having a pair of halves that can be opened and closed, each having a face that abuts the face of the other upon closure, at least one of the halves having a recess portion that has a first portion with a size and shape that conforms to the outer surface of the proximal end of the prosthesis; b) the recess portion having a second portion that is spaced from and surrounds the prosthesis stem so that a distal sleeve can be added to the stem while the prosthesis is occupying a position in the cassette; and c) the recess portions including a recess for accommodating a modular pad.
 10. The apparatus of claim 9 wherein the cassette includes equally sized recessed portions on each respective cassette half.
 11. A container for a sterile medical prosthesis comprising:a) a medical prosthesis having a prosthesis body and a removable modular portion that can be connected to the body; b) a cassette having a pair of halves of corresponding size, each having a face that abuts the face of the other upon closure; c) a recess portion on at least one half of the cassette that conforms generally to the outer surface of the medical prosthesis; d) a bore of the cassette being formed by the recess portion upon closure of the cassette halves, the bore defines generally the outer surface of the prosthesis and includes a portion for conforming to the modular portion of the prosthesis; e) so that the cassette bore supports the prosthesis for allowing an impact load to be applied to the removable modular portion; and f) the cassette bore sized and shaped to hold the body and the modular portion upon closure of the cassette; and g) an outer housing having an interior that can contain the cassette, enabling the cassette to be sterilized for providing a sterile environment to the medical prosthesis.
 12. The apparatus of claim 11 wherein the cassette interior is sized and shaped to conform to the medical prosthesis.
 13. The apparatus of claim 11 wherein each cassette half has a recess that respectively cradles an anterior or a posterior portion of the prosthesis.
 14. The apparatus of claim 11 wherein the cassette is further comprised of a web member that connects the cassette halves at respective peripheral portions of each cassette half.
 15. The apparatus of claim 11 further comprising a release liner that registers upon the outer housing for sealing the interior to form a sterile environment with the housing.
 16. The apparatus of claim 11 wherein the outer housing has a peripheral flange portion that defines an attachment for the release liner to the outer housing.
 17. The apparatus of claim 11 wherein the cassette is generally rectangularly shaped and having parallel side wall portions and the medical prosthesis is oriented along an axial line that is generally parallel to the parallel side walls.
 18. A container for a sterilized medical prosthesis, comprising:a) a medical prosthesis with a body portion and a removable modular portion that can be impact loaded to the body for fitting tightly thereto during assembly; b) a plastic disposable cassette having a recess that is shaped to conform generally to at least a portion of the prosthesis; c) an outer housing for containing both the cassette and the prosthesis; d) a release liner for covering the outer housing and cassette to define a sterile environment for the cassette and the medical prosthesis; and e) the cassette having a bore defining a structural support for the prosthesis body during an impact loading of the modular portion to the body and wherein the cassette can be closed to accommodate the assembled prosthesis body and modular portion.
 19. A sterilizable container for a medical prosthesis comprising:a) a modular hip prosthesis having a lower cylindrical stem, a proximal portion with anterior and posterior sides, a neck portion, modular pads and a distal sleeve for changing the outer shape of the prosthesis; b) cassette means for holding the prosthesis and having a pair of cassette halves that can be opened and closed, each having a face that abuts the face of the other upon closure, at least one of the halves having a recess portion that conforms generally to the outer surface of the prosthesis; c) the recess portion having a continuous wall that is spaced from and surrounds the stem so that a distal sleeve can be added to the stem while the prosthesis is occupying a position in the cassette; d) the recess portion including a recess for accommodating the modular pad; and e) an outer housing covering the cassette and which enables the cassette and prosthesis to be sterilized. 